Protective closure member and process for using the same

ABSTRACT

A protective closure member particularly adapted for closing, the slot opening of a structural support element, such as a channel, during the process of embedding said element in a castable matrix, such as concrete. The closure member having a configuration complementary to portions of the support element to provide mutual interlocking and/or positioning means.

United States Patent [72] Inventor Carl Henry LaLonde Warren, Ohio [21 1 Appl. No. 693,593 [22] Filed Dec. 26, 1967 [45] Patented Aug. 17, 1971 [731 Assignee The Youngstown Sheet and Tube Company Mahoning, Ohio [54] PROTECTIVE CLOSURE MEMBER AND PROCESS FOR USING THE SAME 2 Claims, 5 Drawing Figs.

[52] U.S.C1. 52/710, 52/701, 52/731 [51] Int. E04b 1/38 [50] FieldolSearch 52/701, 710, 704, 699, 624, 730, 731, 716, 309, 312; 249/83, 91, 35; 25/131, D16. 22; 49/486, 490, 489, 491

[56] References Cited UNITED STATES PATENTS 2,075,262 3/1937 Boettnermm r. 52/699 2,667,951 2/1954 Gall 52/399 2,898,758 8/1959 Henrickson 25/131 R 3,034,609 5/1962 Young .1 52/730 X 3,195,698 7/1965 Codrea....,.. 52/731 X 3,327,438 6/1967 Cooper 52/731 2,934,802 5/1960 Shekter 49/488 3,004,308 10/1961 Young 49/489 X 3,299,596 1/1967 Neal 52/716 3,333,364 8/1967 Herr 49/490 X 3,360,887 1/1968 Parks r 49/490 Primary Exaniiner.lohn E. Murtagh Attorney-John Stelmah ABSTRACT: A protective closure member particularly adapted for closing, the slot opening of a structural support element, such as a channel, during the process of embedding said element in a castable matrix, such as concrete. The closure member having a configuration complementary to portions of the support element to provide mutual interlocking and/or positioning means.

PATENTEDAUGI 7197: 1595,3536

ZNVENTOE CARL H ZALO/VDE by 329 L H/s Ar TOR/V5 Y v PROTECTIVE CLOSURE MEMBER AND PROCESS FOR USING THE SAME BACKGROUND OF THE INVENTION This invention generally relates to building and structural elements of the insert type that are embedded in castable materials, such as concrete walls, which elements are employed to mountedly support other structures or units. More particularly, this invention relates to protective means for openings in such elements during the'process of embedding the elements in the casting material.

Structural elements, which are generally U-shape with inwardly turned flanges, and which define a generally continuous slot at the opening of the U, are employed in concrete construction, both with cast in situ and precast sections. These insert elements are fastened, generally by nailing, to the inside of a concrete form before the concrete is poured or cast. The elements are positioned with the continuous slots being immediately adjacent and facing the bearing surface of the concrete form." After the concrete, or other castable material, is poured and set, the forms are removed. Thus the continuous slots are exposed to view and to receive mounting brackets for supporting other structures. It has been deemed desirable to provide a protective member which closes off the continuous slot during the casting process to deter the flowing or seeping of the castable material between the concrete form" and the mating surface of the structural element.

A protective member which has been previously employed is an inverted U form, and of waxed cardboard construction. However, such cardboard members have certain disadvantages. One of these disadvantages is the necessity of providing a separate size for a corresponding height size structural element because the U-legs of the cardboard member bottom" on the base of the structural element U. Also, it has been deemed necessary to tape the cardboard to the structural element every few feet in order to retain the cardboard member in the slot. Another disadvantage lies in the fact that such members can easily become tilted and thus lose their effectiveness for their designated function. Further, it is sometimes necessary to cut the structural elements in the field, i.e. the job site, by means of liquid cooled saws. In such event and in order to prevent degradation of the cardboard inserts by the liquid, it becomes necessary to remove the cardboard and then reinsert it after the cutting operation.

The use of tapes has also been suggested heretofore as closure means for structural elements duringa casting in process. The effectiveness of the tape is contingent upon, to a large extent, the dexterity and skill of the applicator. Even when skillfully applied, such tapes are susceptible to being easily dislodged during handling for shipment and installation procedures.

Metal decorative closure strips for U-shape channel structural elements are also known. However, while these metal strips are satisfactory for decorative purposes after installation is complete, they are unsatisfactory as protective strips during installation for reasons which will become apparent from the description of this invention.

OBJECTS AND SUMMARY OF THE INVENTION It is an object of this invention to provide facile method and means for protectively closing the openings of embedded structural elements during the embedding process.

It is another object of this invention to provide method and means for fastening a protective closure member, to a metal structural member to be embedded, without the need of extraneous securing means.

A further object of this invention is to provide a protective closure member of extruded form and which is not adversely affected by liquids.

A still further object of this invention is to provide a protective closure member which is resilient to facilitate installation in the opening of a structural element but yet is sufficiently rigid so as not to become easily dislodged during regular handling.

Briefly, the objects are attained by providing a protective closure member, preferably of resinous material, either natural or synthetic, and most preferably of the styrene type. The member is extruded in a form having a configuration complementing the configuration of the structural element wall portion defining the opening to be closed. The complementary portions provide interlock means which obviates the necessity for extraneous fastening means. This feature, inter alia, ena bles the closure member to be installed in the structural element at the plant of the fabricator. Thus a burdensome task is eliminated on behalf of the contractor who is responsible for installing the structural element in a castable matrix. Further, these features permit the closure member to be installed without concern of becoming dislodged. The closure member has characteristics of resiliency which enable it to be snapped in place and yet maintain positive sealing engagement with surfaces of the structural element, which sealing engagement serves to deter the entry of contaminants through the opening of the structural elements. The structural configuration of the closure member contributes further to the resiliency of the extruded resinous material. The configuration of the closure member is also of the type which does not require bottoming with the structural element for positioning. Consequently, the closure member of this invention will fit U- shaped structural elements of different heights and in that sense may be termed universal. The use of resinous material enables the closure member of this invention to be readily pierced by the usual securing means, such as by nails or screws, employed to secure the structural element to the form for forming the castable (concrete) material.

DESCRIPTION or THE DRAWING The invention will be more fully understood and further objects and advantages thereof will become apparent when reference is made to the following detailed description and to the accompanying drawing, in which:

FIG. I is a fragmentary oblique view of a slotted channel structural element cast in concrete, with a protective closure member of this invention inserted in the slot of the element, and with a wooden casting form;

FIG. 2 is a cross-sectional view of a preferred embodiment of the closure member of this invention in connection with a slotted channel element;

FIG. 3 is a view similar to FIG. 2 but with the closure member being flexed by a form surface;

FIG. 4 is a cross-sectional view of an alternate embodiment of a closure member; and

FIG. 5 is a plan view of a fragmentary strip of the closure members shown in FIGS. 2 and 4.

DESCRIPTION OF PREFERRED EMBODIMENT Referring to FIG. 1 of the drawing, the protective closure member 10, forming a part of this invention, is there shown as being fastened, together with structural element or channel 12, by nail 14 to a wooden backup or casting form member 16. The channel 12 is embedded in the cast matrix of concrete 18.

The channel I2 is preferably formed from sheet metal to a substantially U-shaped cross-sectional configuration. For (as per the figures) purposes of description, the mutually opposing vertical portions 20R and 20L may be termed the legs 20 of the U and the interconnecting web 24 may be termed the base. Flange portions 26R and 26L extend inwardly from legs 20R and 20L, respectively, and define therebetween a slotted opening 30 into which the closure member 10 fits.

As indicated above, the channel 12 is fastened to form 16 to deter shifting during the casting procedure. The channel 12 may also optionally be provided with one or more lugs 28 to facilitate locking the channel 12 within the matrix 18. To facilitate the fastening, the base 24 is provided with openings 25 through which the nails 14 may extend. Since the nails 14 must also extend through the closure member 10, it is advantageous to fabricate the member from material, which is pierceable by securing means, such as nail l4, and which will hug" the shank of the nail 14 so that concrete will not seep through the'opening made by the nail. In this respect a metal closure member would be disadvantageous since most metal closure members would require preformed openings for the nails. Also, special means would be required to align the openings in such metal closure members with the openings in the base 24 of the structural element 12.

After the matrix 18 is cured or set, the form 16 is removed,

7 thus exposing the closure strip member 10 to view. The closure member 10 may be left in place until such time the structural element 12 is ready to be used as a support member. In other words, the closure member 10 may be used during construction as a protective device to deter construction debris and other contaminants from entering the channel of the structural element 12. After the closure element 10 is removed, the nails 14 may be clipped off." A further feature of employing resinous material for the closure member 10 is that such member may be molded or extruded in bright colors which can serve to readily identify the location of the structural element 12 in a ceiling or floor construction.

The flanges 26R and 26L form the obverse side of the channel 12, when in installed position, and have respective lip portions 34R and 34L extending therefrom, interiorly of the element 12. The terminals of lip portions 34 provide landing 38 for clips or other mounting accessories to be mounted.

The closure member 10 is preferably of resinous plastic material extruded in a generally U-shape in cross section, having mutually opposing legs 42 and base 46. The legs 42R and 421. are preferably of the same size and configuration, but are of opposite hands. For purposes of description those components, or parts which are similar but of opposite hand are designated in the drawing with similar numerals but are distinguished by the letter suffixes R and L. Each leg 42 has a vertically extending portion 48 and a rim portion 50. The portion 48 is of a height which generally corresponds to the height of lip 34 but is preferably of a height which will cause the underside 52 of rim 50 to bear against the edge of landing 38 when the closure strip 10 is inserted, with the free or rim ends of the U-legs first, and snapped" into position within opening 30.

The base 46 is provided with positioning lip portions 60 which extend laterally outward from the junctures 62 formed by the legs 42 and the base 46. The combination of the lip portions 60 with the rim portions 50 provide positioning means for vertically positioning the closure member 10 in respect to the structural element 12 when snapped into place. Since the closure member 10 does not require bottoming for positioning within the element 12, the same size closure member 10 will fit most U-shaped structural elements of the type illustrated and described but which may be of different heights. Preferably, at least a portion of the base 46 protrudes or extends closer to the viewing plane than the obverse side of the lip portions 60, when viewed from a plane corresponding to the obverse side of the closure member 10. Stated in another manner: at least a portion of the bottom surface of base 46 extends more anteriorly than the corresponding side of the lip portion 60 in respect to the base side of the U-closure member. The protruding portion may be defined by an increased thickness of the base as compared to the thickness of a lip portion 60, as shown in FIG. 2, or by depending the lip portions 60 from the vertical legs 42. Alternatively, the protruding portion may be defined by providing the base 46A of member 10A with a slight convexity as may be observed in FIG. 4.

The protrusion of the base 46 contributes to tighter sealing engagement of the member 10 with the element 12 when the element 12 is secured and pulled up tight to a surface ofa casting form, such as form 16. As may be seen in FIG. 3, when the base is contacted by the form 16, the base flexes and transmits the flexing action to the rim 50, which rim tends to ride up the edge of landing 40 and the vertical leg 48 moves into closer contact with lip 34. Also, particularly intimate contact is established at the radius of curvature of the juncture of flange 26 and leg 34 by the inside curvilinear surfaces of lips 60.

It is to be noted that the legs 42 of the member 10 are junctured to the base 46 in a manner such that the junctures are free of a doubled-back base portion. Consequently, the force applied to the protrusion of base 46 will be transmitted directly to the legs 42 and cause them to flex into increased sealing engagement with the lip portions 34 of the element 12. If the positioning lips 60 were formed by doubling back the base, any initial force would merely tend to compress the mutually opposing doubled-back portions into closer relation.

The invention provides a process of preparing a structural channel element for casting in a castable matrix in a manner whereby the matrix is deterred from filling in a channeled portion of the element through a slotted opening, which opening is on an obverse side of the element after casting. The flexible and resilient generally U-shaped closure member 10 is inserted into element 12 to cover opening 30 and is engagingly positioned in respect to element 12 by means of rim portions 50 and lip portions 60, which rim and lip portions are in spaced relation to form pockets therebetween adapted to receive complementary portions, lips 34, of channel 12. The closure member 10 and element 12 are secured to casting form structure 16 by extending a securing member, nail 14, through the base side 24 of element 12 into a surface of structure 16 which mutually engages the base 46 of closure member 10. The surface is then drawn with sufficient tightness to cause legs 34 to flex into increased sealing engagement with structural element 12. The flexing is facilitated by initially engaging the surface with the closure member, during the tightening step, by contact with a protruding portion forming a part of the base 46. The protrusion is preferably formed by providing the base with a thickness greater than the average thickness of other parts of the U. The lips 60 are preferably junctured to element 12 at points displaced from the plane corresponding to the extreme obverse side, in a manner whereby the junctures form parallel lines, to further facilitate flexing and mating of the curvilinear surfaces on the reverse sides of the lips with the round corners of flanges 26.

The use of waterproof plastic or resinous materials deters degradation in the field from weathering and enables the closure member to be cut, by means of fluid-cooled cutting apparatus, without having to be removed from the structural element. Thus, considerable handling time is saved.

What I claim is:

1. In combination with a structural element having a slotted opening on an obverse side, a protective resinous closure member having:

a. a generally U-shaped cross-sectional configuration, with the bottom surface of the U base forming an obverse side and with the legs of the U extending away from the reverse side;

. said legs having rim portions near their free ends; and

c. lip portions extending laterally outwardly from its sides near the base of the U, and which lip portions are in spaced relation with said rim portion to form pockets receiving complementary portions of said structural element and to form means for vertically positioning said closure member in respect to said structural element,

. at least a portion of said bottom surface being more anterior than said lip portions in respect to the base side of said U.

2. In combination with a channel structural element having a generally U-shaped configuration with the opening between the legs of the channel of the U forming an obverse side and with the legs of the channel U being interiorly upturned to define flange portions terminating in landings, a protective closure member having:

a. a generally U-shaped cross-sectional configuration, with the base of the closure member U being anterior of said obverse side and with the legs of the closure member U extending interiorly of said element;

forming means for vertically positioning said closure member in respect to said channel element; and

e. at least a portion of the bottom surface of said base being more anterior than said lip portions, in respect to said ohverse side. 

1. In combination with a structural element having a slotted opening on an obverse side, a protective resinous closure member having: a. a generally U-shaped cross-sectional configuration, with the bottom surface of the U base forming an obverse side and with the legs of the U extending away from the reverse side; b. said legs having rim portions near their free ends; and c. lip portions extending laterally outwardly from its sides near the base of the U, and which lip portions are in spaced relation with said rim portion to form pockets receiving complementary portions of said structural element and to form means for vertically positioning said closure member in respect to said structural element, d. at least a portion of said bottom surface being more anterior than said lip portions in respect to the base side of said U.
 2. In combination with a channel structural element having a generally U-shaped configuration with the opening between the legs of the channel of the U forming an obverse side and with the legs of the channel U being interiorly upturned to define flange portions terminating in landings, a protective closure member having: a. a generally U-shaped cross-sectional configuration, with the base of the closure member U being anterior of said obverse side and with the legs of the closure member U extending interiorly of said element; b. said closure member legs terminating in rim portions which engage the edges of said landings; c. lip portions extending laterally outwardly from its sides and engaging said flange portions at said obverse side of said channel element; d. said closure member lip portions and said rim portions forming means for vertically positioning said closure member in respect to said channel element; and e. at least a portion of the bottom surface of said base being more anterior than said lip portions, in respect to said obverse side. 